Insulating container

ABSTRACT

An insulating device can include an aperture having a waterproof closure which allows access to the chamber within the insulating device. The closure can help prevent any fluid leakage into and out of the insulating device if the insulating device is overturned or in any configuration other than upright. The closure also prevents any fluid from permeating into the chamber if the insulating device is exposed to precipitation, other fluid, or submersed under water. This construction results in an insulating chamber impervious to water and other liquids when the closure is sealed.

This application is a continuation application of U.S. application Ser.No. 14/831,641, filed Aug. 20, 2015 , now U.S. Pat. No. 9,796,517, whichis a divisional of U.S. application Ser. No. 14/479,607, filed on Sep.8, 2014 (now U.S. Pat. No. 9,139,352, issued Sep. 22, 2015, which claimspriority to U.S. Application No. 61/937,310 filed on Feb. 7, 2014, whichis incorporated fully herein by reference.

FIELD

The present disclosure relates generally to non-rigid, portable,insulated devices or containers useful for keeping food and beveragescool or warm, and, more particularly, an insulating device with awaterproof closure.

BACKGROUND

Coolers are designed to keep food and beverages at lower temperatures.Containers may be composed of rigid materials such as metal or plasticsor flexible materials such as fabric or foams. Coolers can be designedto promote portability. For example, rigid containers can be designed toincorporate wheels that facilitate ease of transport or coolers can bedesigned in smaller shapes to allow individuals to carry the entiredevice. Non-rigid containers can be provided with straps and/or handlesand may in certain instances be made of lighter weight materials tofacilitate mobility. Non-rigid coolers that maximize portability can bedesigned with an aperture on the top that allows access to the interiorcontents of the cooler. The aperture can also be provided with aclosure.

SUMMARY

This Summary provides an introduction to some general concepts relatingto this invention in a simplified form that are further described belowin the Detailed Description. This Summary is not intended to identifykey features or essential features of the invention.

Aspects of the disclosure herein may relate to insulating devices havingone or more of (1) a waterproof closure (2) an outer shell, (3) an innerliner, (4) an insulating layer floating freely in between the outershell and the inner liner, or (5) a waterproof storage compartment.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing Summary, as well as the following Detailed Description,will be better understood when considered in conjunction with theaccompanying drawings in which like reference numerals refer to the sameor similar elements in all of the various views in which that referencenumber appears.

FIG. 1A shows a left front perspective view of an example insulatingdevice in accordance with an aspect of the disclosure;

FIG. 1B shows a frontside perspective view of the example insulatingdevice of FIG. 1A without the shoulder strap;

FIG. 2 shows a backside perspective view of the example insulatingdevice of FIG. 1A without the shoulder strap;

FIG. 3A shows a top perspective view of the example insulating device ofFIG. 1A without the shoulder strap;

FIG. 3B shows a top view of a portion of the example insulating deviceof FIG. 1A;

FIG. 3C shows a portion of an alternate top perspective view of theexample insulating device of FIG. 1A;

FIG. 4 shows a bottom perspective view of the example insulating deviceof FIG. 1A;

FIG. 5A illustrates a schematic of a cross-sectional view of the exampleinsulating device of FIG. 1A;

FIG. 5B illustrates another schematic of an enlarged portion of across-sectional view of the example insulating device of FIG. 1A;

FIG. 6 illustrates an exemplary process flow diagram for forming aninsulating device;

FIGS. 7A-7J illustrate exemplary methods of forming an insulatingdevice;

FIGS. 8A and 8B depict perspective views of an alternative exampleinsulating device.

FIG. 9 depicts an example test method for determining if an insulatingdevice maintains the contents therein.

FIG. 10 depicts an example test for determining the strength of aninsulating device.

DETAILED DESCRIPTION

In the following description of the various examples and components ofthis disclosure, reference is made to the accompanying drawings, whichform a part hereof, and in which are shown by way of illustrationvarious example structures and environments in which aspects of thedisclosure may be practiced. It is to be understood that otherstructures and environments may be utilized and that structural andfunctional modifications may be made from the specifically describedstructures and methods without departing from the scope of the presentdisclosure.

Also, while the terms “frontside,” “backside,” “top,” “base,” “bottom,”“side,” “forward,” and “rearward” and the like may be used in thisspecification to describe various example features and elements, theseterms are used herein as a matter of convenience, e.g., based on theexample orientations shown in the figures and/or the orientations intypical use. Nothing in this specification should be construed asrequiring a specific three dimensional or spatial orientation ofstructures in order to fall within the scope of the claims.

FIGS. 1-4 depict an exemplary insulating device 10 that can beconfigured to keep desired contents stored cool or warm for an extendedperiod of time. The insulating device can generally include an outershell 501, a closure 301, an insulating layer 502, and an inner liner500. As shown in FIG. 3C, the inner liner 500 forms a chamber orreceptacle 504 for receiving the desired contents therein. As shown inFIG. 1A, various handles, straps, and webs (e.g. 210, 212, 218, 224) canalso be included on the insulating device 10 for carrying, holding, orsecuring the insulating device 10.

The insulating device 10 can be configured to keep desired contentsstored in the receptacle 504 cool or warm for an extended period oftime. In one example, the insulating device 10 can also be designed tomaintain water inside the inner chamber or receptacle 504, and theinsulating device 10 can be configured to be water “resistant” from theoutside in. In other words, insulating device 10 can be formed “watertight” inside the inner liner 500, and water cannot leak into the innerliner 500 from the outside or out from the inside of the inner liner 500when the closure 301 is in the closed position.

FIG. 4 depicts a bottom view of the insulating device 10. As shown inFIG. 4 the insulating device 10 may include a base 215 and a basesupport ridge 400. The base support ridge 400 can provide structuralintegrity and support to the insulating device 10 when the insulatingdevice 10 is placed onto a surface.

In one example, as shown in FIGS. 3A and 4, the top of the outer shell501 has a first perimeter circumference (T_(cir)) and the bottom of theouter shell 501 has a second perimeter circumference or a base perimeter401 (B_(cir)). The circumference of the top of the outer shell 501 canbe equal to the circumference on the bottom when folded into a cylinder,and B_(cir) can be equal to T_(cir). In one example, the firstcircumference and the second circumference can both have an oval shapeto form an elongated or elliptical cylinder. In one example, the topouter layer 501 a can have a length of 23.5 inches and a width of 5.5inches. Therefore, the length to width ratio of the top outer layer 501a can be approximately 4.3. Additionally, the base 215 can have a lengthof 20.0 inches and a width of 12.25 inches. Therefore, the length towidth ratio of the base 215 is approximately 1.6. In this example, thelength to width ratio of the upper wall can be greater than the lengthto width ratio of the base.

In one example, as shown in FIG. 5A the inner layer or inner liner 500can be formed of a top inner liner portion or first portion 500 a, aninner layer mid portion or second portion 500 b, and an inner layerbottom portion 500 c. The top inner liner portion 500 a, the inner layermid portion 500 b, and the inner layer bottom portion 500 c are securedtogether, by for example welding, to form the chamber 504. The chamber504 can be a “dry bag,” or vessel for storing contents. In one example,after the top inner liner portion 500 a, the inner layer mid portion 500b, and the inner layer bottom portion 500 c are secured or joinedtogether, a tape, such as a TPU tape can be place over the seams joiningthe sections of the chamber 504. The inner liner 500 can, thus, eithermaintain liquid in the chamber 504 of the insulating device 10 orprevent liquid contents from entering into the chamber 504 of theinsulating device 10. In one example, as will be described in furtherdetail below, the inner liner 500 can be suspended in the insulatingdevice 10 by only the closure 301.

The insulating layer 502 can be located between the inner liner 500 andthe outer shell 501, and can be formed as a foam insulator to assist inmaintaining the internal temperature of the receptacle 504. In oneexample, the insulating layer 502 can be a free floating layer that isnot attached directly to the outer shell 501 or the inner liner 500. Theinsulating layer 502 can be formed of a first portion 502 a and a secondportion or base portion 502 b. The first portion 502 a and the secondportion 502 b can be formed of an insulating foam material as will bedescribed in further detail below.

The first portion 502 a can have a rectangular shape that maintains itsform when folded into a cylinder and placed in between the inner liner500 and the outer shell 501 and when encased from above by the outershell 501. The insulating layer 502 maintains its shape which results inthe basic oval-cylindrical shape of the insulating device 10. Therefore,similar to the outer shell 501, the top of the insulating layer 502 hasa first perimeter circumference, and the bottom of the insulating layer502 has a second perimeter circumference. The first perimetercircumference of the insulating layer 502 can be equal to the secondperimeter circumference of the insulating layer 502.

The base portion 502 b can be included to provide additional insulationalong the insulating device 10 at base 215. The base portion 502 b canbe formed as an oval shape to close off a lower opening 506 formed bythe cylindrical shape of the insulating layer 502.

Additionally, the bottom portion of the insulating device 10 can includean additional base-support layer 505, which adds to the insulation andthe structural integrity of the insulating device 10. The base supportlayer 505 may also provide additional protection around the bottom ofthe insulating device 10. In one example, the base support layer 505 canbe formed from EVA foam. The base support layer 505 may include acertain design such as a logo or name that can be molded or embosseddirectly into the material. The base support ridge 400, which providesstructural integrity and support to the insulating device 10 can also bemolded or embossed directly into the base support layer 505. In oneexample, the base support layer 505 and the base portion 502 b can bedetached for ease of assembly.

The outer shell 501 can be formed of a top outer layer portion or firstshell portion 501 a, an outer layer or second outer shell portion 501 b,and a bottom or third shell portion 501 c. The outer shell 501 providesa covering for the insulating device 10. In one example, the insulatinglayer 502 can be suspended freely within the outer shell 501. However,it is contemplated that any of the layers could be secured or formed asa one-piece integral structure. The outer shell 501 can be configured tosupport one or more optional handles or straps (e.g. 210, 212, 218). Inthis regard, the outer shell 501 can also include multiple reinforcementareas or patches 220 that are configured to assist in structurallysupporting the optional handles or straps (e.g. 210, 212, 218). Thehandles or straps (e.g. 210, 212, 218) and other attachments can bestitched using threads 222, however these threads 222 do not, in oneexample, extend through the outer shell 501 into the insulating layer502. Rather, the threads are sewn to the patches 220, and the patches220 can be RF welded to the outer shell 501 or by any other methoddisclosed herein.

As shown in FIG. 5A, the first outer shell portion 501 a may be attachedto the second shell portion 501 b by stitching 510. However, the firstouter shell portion 501 a can be attached to the second shell portion501 b using any known method, e.g., polymer welding, or other adhesivearound the entire perimeter of the second shell portion 501 b.

Additionally, in one example, the base-support layer 505 formed from EVAfoam can be secured to bottom or third shell portion 501 c bylamination. The second shell portion 501 b can be secured to the thirdshell portion 501 c and the base-support layer 505 by polymer welding(e.g. RF welding), stitching, or adhesives.

The insulating device 10 can include two carry handles 210 that areconnected to the frontside 216 of the insulating device 10 and thebackside 217 of the insulating device 10. In one particular example, ashoulder strap 218 can be attached via plastic or metal clip to the ring214 attached to side handles 212 to facilitate carrying insulatingdevice 10 over the shoulder. The insulating device 10 may also includeside handles 212 on each end of the cooler. The side handles 212 providethe user with another option for grasping and carrying the insulatingdevice.

Carry handles 210 may also form a slot for receiving rings 214 near thebottom of the attachment point of the carry handles to the insulatingdevice 10. The rings 214 can be secured to the carry handles 210 and theattachment points 213 by stitching, adhesive, or polymer welding and canbe used to help secure or tie down the insulating device 10 to anotherstructure such as a vehicle, vessel, camping equipment, and the like orvarious objects such as keys, water bottle bottles, additional straps,bottle openers, tools, other personal items, and the like.

Additionally, as shown in FIG. 2, webbing formed as loops 224 can besewn onto the straps forming the handles 210 on the back of theinsulating device 10. The loops 224 can be used to attach items (e.g.,carabineers, dry bags) to the insulating device 10. The side handles 212can also provide the user with another option for securing theinsulating device 10 to a structure.

In one example, the carry handles 210, side handles 212, shoulder strap218 and attachment points 213 can be constructed of nylon webbing. Othermaterials may include polypropylene, neoprene, polyester, Dyneema,Kevlar, cotton fabric, leather, plastics, rubber, or rope. The carryhandles 210 and side handles 212 can be attached to the outer shell bystitching, adhesive, or polymer welding.

The shoulder strap 218 can be attached to the insulating device 10 atattachment points 213. The attachment points 213 can be straps that alsoform a slot for receiving rings 214. The rings 214 can provide for theattachment of the shoulder strap 218.

In one example, the rings 214 can be Acetal D-rings. Rings 214 in can beplastic, metal, ceramic, glass, alloy, polypropylene, neoprene,polyester, Dyneema, and Kevlar, cotton fabric, leather, plastics,rubber, or rope. Rings 214 can include other shapes, sizes, andconfigurations other than a “D” shape. Examples include round, square,rectangular, triangular, or rings with multiple attachment points.Additionally, pockets or other storage spaces can be attached to theoutside of the insulating device 10 in addition to the carry handles 210and side handles 212.

In one example, the closure 301 can be substantially waterproof or abarrier to prevent liquid contents from either entering or exiting theinsulating device. Additionally, the closure 301 can be impervious toliquid such that insulating device 10 liquid penetration is prevented atany orientation of the insulating device 10. Also maintaining theclosure 301 in flat plane can assist in providing a water tight seal.

FIGS. 3A-3C depicts top views of the insulating device 10, and depictsthe top outer layer or the first outer shell portion 501 a and theclosure 301. The top outer layer 501 a depicted in FIG. 3A can besecured to the closure 301. In one example, the closure 301 can be awaterproof zipper assembly and can be watertight up to 7 psi aboveatmospheric pressure during testing with compressed air. However, inother examples, the water tightness of the closure 301 can be from 5 psito 9 psi above atmospheric pressure and in other examples, the watertightness of the closure 301 can be from 2 psi to 14 psi aboveatmospheric pressure. The waterproof zipper assembly can include aslider body 303 and pull-tab 302. FIG. 3B shows a magnified view of theclosure 301 that includes bottom stop 304 and teeth or a chain 305. Inone particular example, the waterproof zipper assembly can beconstructed with plastic or other non-metallic teeth 305 to preventinjury when retrieving food or beverages from the inner chamber 504.

As shown in FIG. 3C, the closure 301 is open or unzipped and an aperture512 formed in the outer shell 501 and the inner liner 500 is open andreveals the inner liner 500 and the inner chamber 504. It iscontemplated that the closure or seal 301 can include various sealingdevices in addition to the depicted waterproof zipper assembly in FIGS.3A-3C. For example, Velcro, snaps, buckles, zippers, excess materialthat is folded multiple times to form a seal such as a roll-down seal,seals, metal or plastic clamps and combinations thereof could be used toseal the inner liner 500 and the outer shell 501.

FIG. 8 depicts another exemplary insulating device 1010, which hassimilar features and functions as the example discussed above inrelation to FIGS. 1A-5B in which like reference numerals refer to thesame or similar elements. However, in this example, a loop patch 1015can be provided on the front of the bag. The loop patch 1015 can beconfigured to receive many types of items or a corresponding group ofhooks, which can be placed onto the surface anywhere on various items,such as fishing lures, keys, bottle openers, card holders, tools, otherpersonal items, and the like. The loop patch 1015 can include a logo,company name, personalization, or other customization. The loop patch1015 can be formed of by needle loops and can have a high cycle life ofover 10,000 closures. In addition, the loop patch can be washable and UVresistant to prevent discoloration. The loop patch can be selected basedon a desired sheer and peel strength depending on the types of materialsthat are to be secured to the insulating device 1010.

In the example shown in FIG. 8, additionally, a strip 1013 can beprovided along the bottom of the bag, which can provide additionalstrength and reinforcement to the outer shell 1501, and may enhance theaesthesis of the insulating device 1010.

Example methods of forming the insulating device 10 will now bedescribed. A general overview of an exemplary assembly process of theinsulating device 10 is depicted schematically in FIG. 6. The varioussteps, however, need not necessarily be performed in the orderdescribed. As shown in step 602 first the portions used to form theinner liner 500, the outer shell 501, and the insulating layer 502 canbe formed or cut to size. In step 604, a top cap assembly 300 can beassembled to the closure 301. In step 606, the inner liner 500 can beformed, and in step 608, the top cap assembly 300 can be welded to theinner liner 500. In step 610, the outer shell 501 can be formed. In step612, the insulation layer 502 can be assembled, and in step 616, theinsulation layer 502 can be placed into the inner liner. Finally, instep 618, the top cap assembly 300 can be secured to the outer shell501.

Referring to step 602, as shown in FIGS. 7A and 7B, inner liner topportions or first inner liner portions 500 a and outer layer top portion501 a that form the top cap assembly 300 can be formed or cut to size.FIG. 7C shows a second portion or base portion 502 b of the insulatinglayer 502 being cut or formed to size from stock foam. In this example,the base portion 502 b is cut from the stock foam 530, by cutting tool700. In one example, the cutting tool 700 can be formed in the shape ofthe base portion 502 b.

Referring now to step 604 and FIG. 7D, the top outer layer 501 a and thetop inner liner 500 a can be secured to the closure 301 to form the topcap assembly 300, and the top outer layer 501 a and the top inner liner500 a can be secured to the closure 301 in a flat, horizontal plane.Referring to FIGS. 5A-5B the top outer layer 501 a can be attached bypolymer welding or adhesive to closure 301. In particular as shownschematically in FIG. 5B, the closure 301 can be provided with a firstflange 301 a and a second flange 301 b, which can form waterproof zippertape 306. The top outer layer 501 a can be attached directly to the topsurfaces of the first flange 301 a and the second flange 301 b of theclosure 301. In one example, the first flange 301 a and the secondflange 301 b, can be RF welded to the underside of the top outer layer501 a. In another example, as shown in FIG. 7E, the top inner linerportion 500 a can be provided with tabs 515. Tabs 515 can assist in theassembly process to keep the outer strips of the top inner liner portion500 a in place during assembly and can be removed after the top capassembly 300 is formed.

In one example, the top inner liner portion 500 a can be attached to thestructure of the insulating device 10 as shown schematically in FIG. 5B.In particular, the top inner liner portion 500 a can be attached to thebottom of the closure 301. For example, as shown in FIG. 5B, and a firstend 540 a and a second end 540 b of the top inner liner portion 500 acan be attached to undersides of the first flange 301 a and the secondflange 301 b. The top inner liner portion 500 a and the top outer layer501 a can be attached to the closure 301 by polymer welding or adhesive.Polymer welding includes both external and internal methods. External orthermal methods can include hot gas welding, hot wedge welding, hotplate welding, infrared welding and laser welding. Internal methods mayinclude mechanical and electromagnetical welds. Mechanical methods mayinclude spine welding, stir welding, vibration welding, and ultrasonicwelding. Electromagnetical methods may include resistance, implant,electrofusion welding, induction welding, dielectric welding, RF (RadioFrequency) welding, and microwave welding. The welding can be conductedin a flat or horizontal plane to maximize the effectiveness of thepolymer welding to the construction materials. As a result, a ruggedwatertight seam can be created that prevents water or fluids fromescaping from or into the inner chamber 504.

In a particular example, the polymer welding technique to connect thetop inner liner portion 500 a to the bottom of the closure 301 caninclude RF welding. The RF welding technique provides a waterproof seamthat prevents water or any other fluid from penetrating the seam atpressure up to 7 psi above atmospheric pressure. The insulating device10, therefore, can be inverted or submerged in water and leakage isprevented both into and out of the internal chamber 504 formed by innerliner 500. In one example, the insulating device 10 can be submergedunder water to a depth of about 16 feet before water leakage occurs.However, it is contemplated that this depth could range from about 11feet to 21 feet or 5 feet to 32 feet before any leakage occurs.

Next referring to step 606 and FIG. 7F, the inner layer mid-portion 500b can be formed by RF welding. As shown in FIG. 7F, the inner layermid-portion 500 b can be formed of a rectangular sheet of material. Theinner layer mid-portion 500 b can also be secured to the inner layerbottom portion 500 c in a subsequent step not shown.

Referring to step 608 and FIGS. 7G and 7H, the inner layer mid portion500 b and the inner layer bottom portion 500 c can be secured to the topcap assembly 300 using an RF welding operation.

Referring to step 610, the second shell portion 501 b and the bottomouter shell 501 c, which supports the base support layer 505, can be RFwelded to construct the outer shell 501 for the insulating device 10. Inone example, as shown schematically in FIG. 5A, the top outer layer 501a can be sewed to the perimeter of the second shell portion 501 b toform the outer shell 501 of the insulating device. A fabric binding canbe used to cover the stitched seam edges of the second shell portion 501b and the top outer layer 501 a. This assists in closing or joining theouter shell 501 around the insulating layer 502.

Referring to step 612 and FIG. 71, the insulating layer 502 can beconstructed. In one example the first portion 502 a of the insulatinglayer 502 can be formed into a rectangular shape and can be secured atthe smaller sides of the rectangular shape using double sided tape toform the cylindrical shape. The second portion or base portion 502 b canbe formed into an oval shape that can have a smaller circumference thanthe circumference of the cylindrical shape of the first portion 502 a.The second portion 502 b can be secured to the first portion 502 a alsousing a double-sided tape to form the insulating layer 502. In oneexample, double sided tape can be placed either around the innerperimeter of the first portion 502 a cylinder or around the outerperimeter of the base portion 502 b, and the base portion 502 b can beadhered to the first portion 502 a. Other methods of securing the baseportion 502 b to the first portion 502 a to form the insulating layer502 are contemplated, such adhesives or polymer welding.

Referring to step 614, the assembled insulating layer 502 can be placedinto the outer shell 501. In step 616, the formed inner liner 500 andtop cap assembly 300 can be placed into the insulating layer 502.

Finally in step 618 the top cap assembly 300 can be sewed to the outershell 501 to form seams 520 as depicted schematically in FIG. 5A. Inthis way, neither the inner liner 500 nor the outer shell 501 need to bebound to the insulating layer 502. Also the inner liner 500 is onlyconnected to the closure 301 and the closure 301 holds the inner linerand the outer shell 501 together, which results in a simplermanufacturing process. After sewing the top cap assembly 300 to theouter shell 501, a fabric binding is added to cover the raw edgesadjacent the seams 520. Thus, the top seams 520 can be the only primaryseams on the insulating device 10 that are created by stitching.

In one particular example, the inner liner 500 and the outer shell 501can be constructed from double laminated TPU nylon fabric. Nylon fabriccan be used as a base material for the inner liner 500 and the outershell 501 and can be coated with a TPU laminate on each side of thefabric. The TPU nylon fabric used in one particular example is 0.6millimeters thick, is waterproof, and has an antimicrobial additive thatmeets all Food and Drug Administration requirements. Alternativematerials used to manufacture the inner shell or chamber 504 and outershell 501 include PVC, TPU coated nylon, coated fabrics, and otherweldable and waterproof fabrics.

A closed cell foam can be used to form the insulating layer 502 that issituated in between the inner liner 500 and the outer shell 501. In oneexample, the insulating layer 502 is 1.0 inches thick. In one example,the insulating layer 502 can be formed of NBR/PVC blend or any othersuitable blend. The thermal conductivity of an example insulating layer502 can be in the range of 0.16-0.32 BTU.in/(hr·sqft·° F.), and thedensity of the insulating layer 502 can be in the range of 0.9 to 5lbs/ft³. In one example, the thermal conductivity of the insulatinglayer 502 can be in the range of 0.25 BTU.in/(hr·sqft·° F.), and thedensity of the insulating layer 502 can be 3.5 lbs/ft³.

The foam base can be manufactured from an NBR/PVC blend or any othersuitable blend. In addition to the base portion 502 b of the insulatinglayer 502, the insulating device 10 may also include an outer basesupport layer 505 constructed of foam, plastic, metal or other material.In one example, the base portion 502 b can be detached from the basesupport layer. In one example, the base portion 502 b is 1.5 inchesthick. Additionally as shown in FIG. 5A, the EVA foam base support layer505 can be 0.2 inches thick. Although the base support layer 505 islaminated to the base outer layer 501 c, in an alternative example, thebase support layer 505 can be attached to the bottom of the base portion502 b by co-molding, polymer welding, adhesive, or any known methods.

A heat gain test was conducted on the exemplary insulating device 10.The purpose of a heat gain test is to determine how long the insulatingdevice can keep temperature below 50° F. at an ambient of 106° F.±4 withthe amount of ice based on its internal capacity.

The procedure is as follows:

-   1. Turn on the oven and set to 106° F.±4. Allow the oven to    stabilize for at least one hour.-   2. Turn on the chart recorder. The recorder shall have three    J-thermocouples connected to it to chart the following    temperatures: (1) Test unit, (2) Oven, and (3) Room ambient.-   3. Stabilize the test unit by filling it to half its capacity with    ice water, and allowing it to sit for 5 minutes at room temperature    (72° F.±2).-   4. After 5 minutes, pour out the contents, and immediately connect    the J-thermocouple end to the inside bottom center of the unit. The    thermocouple wire end must be flush to the inside bottom surface and    secured with an adhesive masking tape.-   5. Pour the correct amount of ice ensuring the thermocouple wire is    not moved. Amount of ice is based on 4 lbs. per cubic feet of the    internal capacity of the unit.-   6. Close the lid and position the test unit inside the oven.-   7. Close the oven making sure the thermocouple wires are    functioning.-   8. Mark the start of the chart recorder.

Apparatus: 1. Oven. 2. Ice. 3. Chart Recorder. 4. J-Thermocouples (3).Results: 1. Cold Retention Time: Elapsed time from <32° F. to 50° F. indecimal hours. 2. Heat Gain Rate (° F./Hr): (50° F.−32° F.)÷ElapsedTime=18° F.÷Elapsed Time

In one test of the example insulating device, the heat gain rate equaled1.4 degF./hr assuming 26.5 quarts capacity and used 3.542 lbs of ice forthe test.

The ability of the insulating device 10 to withstand interior leaks canalso be tested to see how well the insulating device maintains thecontents stored in the storage compartment or receptacle 504. In oneexample test, the insulating device 10 can be filled with a liquid, suchas water, and then can be inverted for a predetermined time period totest for any moisture leaks. In this example, the insulating device 10is filled with a liquid until approximately half of a volume of thereceptacle 504 is filled, e.g. 3 gallons of water, and the closure 301is then closed fully to ensure that the slider body 303 is completelysealed into the horseshoe-shaped portion 308. The entire insulatingdevice 10 is then inverted and held inverted for a time period of 30minutes. The insulating device 10 is then reviewed for any leaks.

The insulating device 10 can be configured to withstand being heldinverted for 30 minutes without any water escaping or leaving thereceptacle 504. In alternative examples, the insulating device can beconfigured to withstand being held inverted for 15 minutes to 120minutes without any water escaping or leaving the receptacle 504. Toperform this test, it may be helpful to lubricate the closure to ensurethat the closure is adequately sealed. For example, as shown in FIG. 9,a horseshoe-shaped portion 308 of the closure 301 is provided withlubricant 309.

The strength and durability of the fabric forming the outer shell 501,inner liner 500 and the insulating layer 502 of the insulating device 10may also be tested. In one example, the test can be devised as apuncture test. In particular, this test can be designed as an ASTMD751-06 Sec. 22-25 screwdriver puncture test. In one example, theinsulating device 10 can withstand 35 lbs to 100 lbs of puncture force.

The handle strength and durability of the insulating device 10 can alsobe tested. One such example test is depicted in FIG. 10. As depicted inFIG. 10, the closure 310 can be fully closed, one of the carry handles210 can hooked to an overhead crane 600, and the opposite carry handle210 is hooked to a platform 650, which can hold weight. In one example,the platform 650 can be configured to hold 200 lbs. of weight. Duringthe test, the crane 600 is slowly raised, which suspends the insulatingdevice 10 in a position where the bottom plane of the insulating device10 is perpendicular with the floor. In one example, the insulatingdevice 10 can be configured to hold 200 lbs. of weight for a minimum of3 minutes without showing any signs of failure. In alternative examples,the insulating device can be configured to hold 100 lbs. to 300 lbs. ofweight for 1 to 10 minutes without showing signs of failure.

An exemplary insulating device may include an outer shell, an innerliner, an insulating layer floating freely in between the outer shelland the inner liner, and a waterproof closure. The top of the shell hasfirst perimeter circumference, and the bottom of the shell has a secondperimeter circumference. The first perimeter circumference can be equalto the second perimeter circumference. The closure can be a zipperassembly comprising a plurality of zipper teeth, and the zipper teethcan be formed of plastic or metal. The outer shell can be made of adouble laminated TPU nylon fabric. The inner liner can be made of adouble laminated TPU nylon fabric. The insulating layer can be formed ofa closed cell foam. The insulating layer can be made of a NBR and a PVCblend, and at least a portion of the insulating layer can be constructedwith an EVA foam layer. The outer shell further can include at least oneof a strap or handle. The outer shell further can include at least onering for securing the insulating device.

An exemplary insulating device can include an outer shell, an innerliner, a closure adapted to seal at least one of the outer shell or theinner liner, and an insulating layer between the outer shell and theinner liner. The closure can have a first flange and a second flange,and the outer liner can be secured to top surfaces of the first flangeand the second flange and the inner liner can be secured to bottomsurfaces of the first flange and the second flange. The outer liner andthe inner liner can be connected to the closure by a polymer weld. Theouter shell can have a first circumference and a second circumference,the first circumference and the second circumference both having an ovalshape. The closure can be adapted to be a barrier against fluid. Theclosure can be a zipper apparatus that is watertight up to 7 psi aboveatmospheric pressure.

An exemplary method of assembling a insulating device may includeforming an inner liner having an inner vessel, forming an outer shell,forming an insulating layer between the inner liner and the outer shell,and securing a closure configured to be a barrier against fluidpenetration in and out of the inner vessel wherein the closure issecured in a flat plane and is secured to the outer shell and the innershell. The outer shell and inner shell may only be connected to theclosure and not to the insulating layer between the outer shell andinner liner.

A waterproof polymer weld can be formed between the closure and theinner shell and the closure and the outer shell when the closure, theouter shell, and the inner liner are lying in a horizontal plane. Theouter shell and the inner layer can be formed of a TPU nylon material.The closure can have a first flange and a second flange. The outer linercan be secured to top surfaces of the first flange and the second flangeand the inner liner can be secured to bottom surfaces of the firstflange and the second flange.

The method can also include forming the insulating layer from arectangular shape, and rolling the rectangular shape into a cylindricalshape. The top of the insulating layer has a first perimetercircumference and the bottom of the insulating layer has a secondperimeter circumference. The first perimeter circumference can be equalto the second perimeter circumference.

Another example insulating device can include an outer shell, an innerliner forming a storage compartment, a foam layer floating freely inbetween the outer and inner liner, the foam layer providing insulation,an opening extending through the outer layer and the inner layer, and aclosure adapted to substantially seal the opening. The closure can besubstantially waterproof so as to resist liquid from exiting theopening.

The insulating device can also include an upper wall and a base, theupper wall defining an upper wall circumference, an upper wall lengthand an upper wall width, and the base defining a base circumference, abase length and a base width. The upper wall circumference can be equalto the base circumference and the ratio of the upper wall length to theupper wall width can be greater than the ratio of the base length to thebase width. In one example, a heat gain rate of the insulating devicecan be approximately 1.0-1.5 degF./hr.

Another example method of forming an insulating device may includeforming an inner liner first portion and an outer shell first portion,securing the inner liner first portion and the outer shell first portionto a sealable closure to form a cap assembly, forming an inner linersecond portion and securing the inner liner second portion to the innerliner first portion to form an inner liner, forming an outer shellsecond portion, rolling a rectangular foam portion to form a firstcylindrical foam portion and securing a foam base portion to the firstcylindrical portion to form a foam assembly, inserting the foam assemblyinto the outer shell second portion, inserting the inner liner into thefoam assembly, and stitching the outer shell first portion to the outershell second portion. The inner liner first portion and the outer shellfirst portion can be welded to the closure. The closure can be providedwith at least one flange and the flange can be secured to a bottomsurface of the outer shell first portion and a top surface of the innerliner first portion. The foam can float between the outer shell secondportion and the inner liner second portion.

An example portable insulating device may include an outer liner, aninner liner forming a storage compartment, a foam layer in between theouter and inner liner. The foam layer can be adapted to provideinsulation. The example portable insulating device may also include anopening extending through one of the outer layer and the inner layer anda closing means for substantially sealing the opening. The closure canbe substantially waterproof.

In one example, a portable cooler may include an aperture on the top ofthe cooler that is opened and closed by a zipper apparatus which allowsaccess to a chamber within the cooler. The aperture prevents any fluidleakage out of the cooler if the cooler is overturned or in anyconfiguration other than upright. The zipper assembly also prevents anyfluid from permeating into the cooler chamber if the cooler is exposedto precipitation, other fluid, or submersed under water.

An example method of assembling a zipper apparatus and apertureconfigured to be impervious to water or other liquids and fluids caninclude attachment of a waterproof zipper via material welding to bothan outer shell and an inner liner. This method may result in a chamberimpervious to water and other liquids when the zipper apparatus on theaperture is sealed.

In one example, an insulating device may include an outer shell, aninner liner forming a storage compartment, a foam layer floating formedin between the outer and inner liner, the foam layer providinginsulation, an opening extending through the outer layer and the innerlayer, a closure adapted to substantially seal the opening, the closurebeing substantially waterproof so as to resist liquid from exiting theopening when the insulating device is in any orientation. In oneexample, the top portion of the outer shell can have a first perimetercircumference in a first configuration. The outer shell may include abottom portion, the bottom portion of the outer shell can have a secondperimeter circumference in a second configuration that is different fromthe first configuration, and the first perimeter circumference can beequal to the second perimeter circumference. The first configuration andthe second configuration can be both oval shaped. In one example, theinsulating device may include an upper wall and a base, the upper wallcan define an upper wall circumference, an upper wall length and anupper wall width, and the base can define a base circumference, a baselength and a base width. The upper wall circumference can be equal tothe base circumference and the ratio of the upper wall length to theupper wall width can be greater than the ratio of the base length to thebase width. The cold retention time of the insulating device can beapproximately 11 to 20 hours. However, in one example the cold retentiontime can be 11 to 15 hours. In another example the cold retention timecan be approximately 12.24 hours. The heat gain rate of the insulatingdevice can be approximately 1 to 1.5 degF./hr, and, in one particularexample, the heat gain rate can be approximately 1.4 degF./hr. Thestorage compartment can be configured to maintain a liquid therein whileinverted for greater than 15 minutes. In one particular example, thestorage compartment can be configured to maintain the liquid for aperiod of greater than 30 minutes therein when inverted and a half of avolume of the storage compartment is filled with the liquid.

In one example, the insulating layer can be floating freely in betweenthe outer shell and the inner liner. The insulating layer can be formedof closed cell foam, and the insulating layer can be made of a NBR and aPVC blend. In one example least a portion of the insulating layer can beconstructed with an EVA foam layer. The closure can be a zipper assemblycomprising a plurality of zipper teeth, and the zipper teeth can beformed of plastic.

In one example, the outer shell and the inner liner can be made of adouble laminated TPU nylon fabric. The outer shell further can includeat least one of a strap or handle. The outer shell can include at leastone ring for securing the insulating device. The insulating layer can beconfigured to maintain an internal temperature of the insulating devicebelow 50 degrees Fahrenheit for 65 to 85 hours. The closure can beformed with a first flange and a second flange and the outer liner canbe secured to top surfaces of the first flange and the second flange.The inner liner can be secured to bottom surfaces of the first flangeand the second flange. The outer liner and the inner liner can beconnected to the closure by a polymer weld. In one example, the closurecan be watertight up to 2 to 14 psi above atmospheric pressure. A looppatch may also be provided on the insulating device.

In another example, an insulating device may include an outer shell, aninner liner forming a storage compartment, a foam layer floating inbetween the outer and inner liner, which provides insulation, an openingextending through the outer layer and the inner layer, a closure adaptedto substantially seal the opening. The closure can be substantiallywaterproof so as to prevent liquid from exiting the opening when theinsulating device is inverted for a period of greater than 15 minutes.The heat gain rate of the insulating device can be approximately 1.0 to1.5 degF./hr. The insulting device can include at least one handle. Theat least one handle can be configured to support 100 lbs. to 300 lbs. ofweight for 1 to 10 minutes without showing signs of failure. In oneexample, the insulating device can be configured to withstand 35 lbs. to100 lbs. of puncture force.

An example method of forming an insulating device can include forming aninner liner first portion and an outer shell first portion, securing theinner liner first portion and the outer shell first portion to asealable closure to form a cap assembly, forming an inner liner secondportion and securing the inner liner second portion to the inner linerfirst portion to form an inner liner, forming an outer shell secondportion, rolling a rectangular foam portion to form a first cylindricalfoam portion and securing a foam base portion to the first cylindricalfoam portion to form a foam assembly, inserting the foam assembly intothe outer shell second portion, inserting the inner liner into the foamassembly, and securing the outer shell first portion to the outer shellsecond portion to form the outer shell. The method may also includesecuring a closure configured to be a barrier against fluid penetrationin and out of the inner vessel and forming a waterproof polymer weldbetween the closure and the inner shell and the closure and the outershell when the closure, the outer shell, and the inner liner are lyingin a flat plane.

In an example, the inner liner first portion and the outer shell firstportion can be secured to the closure. The closure can be provided withat least one flange, and the flange can be secured to a bottom surfaceof the outer shell first portion and a top surface of the inner linerfirst portion. The foam can freely float between the outer shell secondportion and the inner liner second portion. The outer shell and innershell are only connected to the closure and not to the insulating layerbetween the outer shell and inner liner. The outer shell can be formedof a TPU nylon material, and the inner liner can be formed from a TPUnylon material. The closure can include a first flange and a secondflange. The outer liner can be secured to top surfaces of the firstflange and the second flange, and the inner liner can be secured tobottom surfaces of the first flange and the second flange. The top ofthe insulating layer can have a first perimeter circumference. Thebottom of the insulating layer can have a second perimetercircumference. The first perimeter circumference can be equal to thesecond perimeter circumference.

The present invention is disclosed above and in the accompanyingdrawings with reference to a variety of examples. The purpose served bythe disclosure, however, is to provide examples of the various featuresand concepts related to the invention, not to limit the scope of theinvention. One skilled in the relevant art will recognize that numerousvariations and modifications may be made to the examples described abovewithout departing from the scope of the present invention.

What is claimed is:
 1. A method of forming an insulating device comprising an outer shell having a bottom base support layer, an inner liner, an insulating layer in between the outer shell and the inner liner, the insulating layer comprising sides and a bottom abutting each other, a closure adapted to substantially seal an opening, the closure being substantially waterproof so as to resist liquid from exiting the opening when the insulating device is in any orientation, the method comprising: forming the inner liner having an inner vessel, forming the outer shell having the bottom base support layer, forming the insulating layer; placing the insulating layer within the outer shell such that the bottom of the insulating layer is unattached to the bottom base support layer, placing the inner liner within the insulating layer; and securing the closure to the outer shell and the inner liner.
 2. The method of claim 1 wherein the outer shell and inner liner are only connected to the closure and not to the insulating layer between the outer shell and inner liner.
 3. The method of claim 1 further comprising forming waterproof polymer welds between the closure and the inner liner and the closure and the outer shell.
 4. The method of claim 1 wherein the outer shell is formed of a TPU nylon material.
 5. The method of claim 1 wherein the insulating layer is a foam layer between the outer shell and the inner liner.
 6. The method of claim 1 further comprising forming the insulating layer to be floating freely in between the outer shell and the inner liner.
 7. The method of claim 1 wherein the closure is a zipper assembly comprising a plurality of zipper teeth, wherein the zipper teeth are formed of plastic or metal.
 8. The method of claim 1 further comprising forming the outer shell and the inner liner from double laminated TPU nylon fabric.
 9. The method of claim 1 further comprising forming the insulating layer from closed cell foam.
 10. The method of claim 1 further comprising forming the insulating layer from a NBR and a PVC blend.
 11. The method of claim 1 wherein at least a portion of the insulating layer is constructed with an EVA foam layer.
 12. The method of claim 1 further comprising attaching at least one of a strap or handle to the outer shell.
 13. The method of claim 1 wherein the closure has a first flange and a second flange wherein the outer shell is secured to top surfaces of the first flange and the second flange and the inner liner is secured to bottom surfaces of the first flange and the second flange.
 14. The method of claim 1 further comprising connecting the outer shell and the inner liner to the closure by a polymer weld.
 15. The method of claim 1 wherein the sides and the bottom of the insulating layer are secured to each other. 